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Zenith CruZer & Sonex Logs
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Date: 11-14-2010
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Number of Hours: 2.30
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Manual Reference: aerovee
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Brief Description: Crank / Cam Install / Set End-Play
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Lots of tedium; simple overall.
Began with installation of the cam tappets. Removed from the packaging & removed the oil/varnish protectant. Installed in the engine case halves. Ensured smooth travel. Removed each one and coated with white lithium assembly lube.
Next, I installed 5 dowel pins - one for each bearing in the right case half, and one for the middle bearing in the left case half. Installed center main bearings, ensuring that they fit over the dowel pins. Lubed the aft main bearing and installed it on the crank.
Installed the crank into the case. At this point, I temporarily assembled the case halves and rotated the crank to ensure that there was no interference between the case and the connecting rods. Removed case half.
Applied white lithium assembly lube to the main and cam bearings. Installed cam; aligned marker dots on the crank with the dot on the cam gear to ensure correct timing. Rolled the cam into position.
Now it was time to set the crankshaft end-play. I installed the flywheel and hand-tightened. I then removed the engine from the engine stand and set it on the bench. I then used my pneumatic impact wrench to crank the flywheel down tight. I tapped the crank to its aft-most position with a rubber mallet. The gap between the flywheel and rear main bearing was about .0345. I found a combination of shims that will yield .004 final end-play (desired goal is between .003 & .006).
Using the impact, I removed the gland nut and tapped-off the flywheel. I remounted the engine to the engine stand.
Note: The instructions say to use a 36mm socket for the gland nut, but the 12-point socket I had would not fit - too tight. I ended up buying a 1 7/16" impact socket, 6 point, which worked very well, and was tight on the nut.
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Installed Crank, Cam & Flywheel
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